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GENERAL

This Service Manual Supplement has been prepared with twopurposes in mind. First, it will acquaint the user with theconstruction of the 1997 Buell S1 Lightning and assist in theperformance of basic maintenance and repair. Secondly, it

will introduce to the professional Buell Technician the latesteld-tested and factory-approved major repair methods. Wesincerely believe that this Service Manual Supplement willmake your association with Buell products more pleasant andprotable.

HOW TO USE YOUR SERVICEMANUAL SUPPLEMENT

1. Check the TABLE OF CONTENTS following thisFORWORD to nd the desired subject.

2. If the information you seek is not in this supplement, referto the corresponding section in the Buell 1996S1 Lightning Service Manual (Part No. 99490-96Y).Check the TABLE OF CONTENTS or INDEX to nd thedesired subject.

3. Information is presented in a denite order as follows:

SpecicationsGeneral/Model Year ChangeAdjustment/TestingRemoval/Disassembly

Cleaning, Inspection, and RepairAssembly/Installation

In gure legends, the number which follows the name of apart indicates the quantity necessary for one completeassembly.

NOTE

To avoid needless disassembly, carefully read all relative service information before repair work is started.

PREPARATION FOR SERVICE

1 WARNING

Gasoline is extremely ammable and highly explosive.Always stop the engine when refueling or servicing thefuel system. Do not smoke or allow open ame or sparksnear the work site. Inadequate safety precautions mayresult in personal injury.

Good preparation is very important for efcient service work.A clean work area at the start of each job will allow you toperform the repair as easily and quickly as possible, and willreduce the incidence of misplaced tools and parts. Amotorcycle that is excessively dirty should be cleaned beforework starts. Cleaning will occasionally uncover sources oftrouble. Tools, instruments and any parts needed for the jobshould be gathered before work is started. Interrupting a jobto locate tools or parts is an unnecessary distraction andcauses needless delay.

SERVICE BULLETINSIn addition to the information presented in this ServiceSupplement, Buell Distribution Corporation will periodicallyissue Service Bulletins to Buell dealers. Service Bulletinscover interim engineering changes and supplementaryinformation.

USE GENUINEREPLACEMENT PARTS

1 WARNING

When replacement parts are required, use only genuineBuell parts or parts with equivalent characteristics(which include type, strength and material). Failure to doso may result in product malfunction and possible injuryto the operator and/or passenger.

To ensure satisfactory and lasting repairs, carefully follow theinstructions and use only genuine Buell replacement parts.This is your assurance that the parts you are using will tright, operate properly and last longer.

FOREWORD

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PRODUCT REFERENCES

1 WARNING

Follow the directions listed on all products. Carefullyread all labels, warnings and cautions before use.Inadequate safety precautions may result in personalinjury.

When reference is made in this Service Manual Supplementto a specic brand name product, tool or instrument, anequivalent product, tool or instrument may be substituted.

Kent-Moore Products

All tools mentioned in this supplement with an “HD”, “J” or “B”preface must be ordered through:

Kent-MooreSPX Corporation29784 Little MackRoseville, Michigan 48066-2298

Telephone: 1-800-345-2233

Sealing and Threadlocking Products

LOCTITE PRODUCTS

Some procedures call for the use of Loctite ® products. If youhave any questions regarding Loctite product usage orretailer/wholesaler locations, please call Loctite Corp. at 1-800-323-5106.

CONTENTSAll photographs and illustrations may not necessarily depictthe most current model or component, but are based on thelatest production information available at the time ofpublication.

Since product improvement is our continual goal, Buellreserves the right to change specications, equipment ordesigns at any time without notice and without incurringobligation.

WARNINGS AND CAUTIONSStatements in this supplement preceded by the word“1 WARNING” or “ 1 CAUTION” are very important. Sincethese items alert you to situations where the possibility ofpersonal injury or vehicle damage exists, please take specialnotice of them.

1 WARNING

A “WARNING” indicates the potential for personal injury,

whether to yourself or others.1 CAUTION

A “CAUTION” indicates that vehicle damage can occur.

1 WARNING

Proper service and repair is important for the safe,reliable operation of all mechanical products. Theservice procedures recommended and described inthis Service Manual are effective methods forperforming service operations. Some of theseservice operations require the use of tools speciallydesigned for the purpose. These special tools should

be used when and as recommended. It is importantto note that some warnings against the use ofspecic service methods, which could damage themotorcycle or render it unsafe, are stated in thisService Manual. However, please remember thatthese warnings are not all-inclusive.

Since Buell could not possibly know, evaluate oradvise the service trade of all possible ways in whichservice might be performed, or of the possiblehazardous consequences of each method, we havenot undertaken any such broad evaluation.Accordingly, anyone who uses a service procedureor tool which is not recommended by Buell must rst

thoroughly satisfy himself that neither his nor theoperator’s safety will be jeopardized as a result.

Wear eye protection when using hammers, arbor orhydraulic presses, gear pullers, spring compressors,slide hammers and similar tools. Be especiallycautious when using pulling, pressing orcompressing equipment. The forces involved cancause parts to y outward with considerable force,possibly resulting in personal injury.

Buell products are manufactured under one or more of the following patents: U.S. Patents – 2986161, 2987934,2998809, 3116089, 3144531, 3144860, 3226994, 3229792, 3434887, 3559773, 3673359, 3709317, Des. 225 626.